Ladies&#39; stretch tube stocking



March 28, 1967 c. A, BERRY 3,310,966

LADIES STRETCH TUBE STOCKING Filed March 2, 1966 F 5 CLYDE A. Bea fi Bypwwm, M m,wy

ATTORNEYS United States Patent 3,310,966 LADZE STRETCH TUBE STOCKING Clyde A. Berry, Valdese, N.C., assignor to Pilot Research Corporation, Valdese, NAIL, a corporation of North Carolina Filed Mar. 2, 1966, Ser. No. 531,248 6 Claims. (Cl. 66-178) This invention relates generally to ladies sheer seamless stretch stockings, and more particularly, to a stretchable tube stocking which is knit of monofilament thermoplastic torque yarns in a single size that has suficient stretchability to fit the complete normal range of leg and foot sizes.

Because of their low cost, ladies non-stretchable tube type stockings have become quite popular in the last few years. These stockings are produced of non-torque monofilament nylon yarn in a full range of sizes by knitting substantially straight cylindrical tubes at a high production rate and thereafter closing the bottom of the tube by sewing. The closed tubes are then boarded (before or after dyeing as is well known in the art) on conventional forms corresponding to the various sizes to shape the tube into a conventional stocking shape; i.e., a relatively wide knee area tapering down through the calf area to a relatively narrow ankle area and terminating in a foot shape with a distinct heel pocket.

Ladies sheer stretchable seamless stockings produced from monofilament torque yarns have also become quite popular in the last few years because of their ability to readily conform to the leg of the wearer and fit several leg and foot sizes. These stockings are produced with reciprocatorily knit heel pockets and with or without reciprocatorily knit toe pockets which are closed by looping or sewing. These stockings are also subsequently boarded on forms otherwise similar to the conventional boarding form except for the provision of a reduced size foot or socalled club foot. This reduced size or club foot is necessary in order to prevent excessive stretching when the stocking is drawn on the boarding form and thus, elimination of the stretchable nature of the stocking foot when subjected to heat-setting temperatures during boarding. Even with these precautions, however, it is still necessary to knit and board these stockings in three different sizes (usually small, medium and large) in order to cover the complete normal stocking size range of 8 /2 to 11 /2 since the boarding operation nevertheless results in setting the fabric in stretched condition to limit the amount of stretchability in the foot area.

The foregoing problems encountered in producing stretchable seamless stockings are compounded in the tube stocking art. This is because the normal tendency in boarding tubes is to stretch the tube downwardly on the boarding form, and since there is no heel pocket in the tube to serve as a reference point, almost all of the stretch is pulled out of the foot, particularly in the area of the heel. Thus, at best, with rigid controls in the boarding operation, stretchable tube type stockings would still have to be made in at least three size ranges because the normal stretch in the foot would be pulled out and set to restrict the stretch to an even greater degree than the stretch is restricted in ordinary seamless stretch stockings with reciprocatorily knit heel pockets. As a result of these problems, ladies sheer stretchable tube type stockings have not heretofore been practical.

With the foregoing in mind, it is a primary object of the present invention to provide ladies sheer seamless stretchable tube stockings and a method of forming and finishing the same so that the stockings may be produced in a single size which has sufficient stretchability to fit the entire normal range of leg and foot sizes and which may be ice knit and boarded at a high production rate to thereby decrease the cost of the stockings.

The stretchable tube stocking of this invention is characterized by the absence of the usual knitted or shaped heel projection and by the presence of substantially uniform stretch characteristics or stitch distortion throughout the heel and foot area of the stocking. Instead of the usual heel projection, the heel and foot portion of the stocking comprises an extension of the leg portion which is substantially in line with the leg and of substantially uniform width throughout. The uniform stitch distortion or stretch characteristics of this fabric cause the fabric to stretch and cling or conform to the foot of the wearer when worn in a substantially uniform manner without wrinkles, bulges or uncomfortable tightness. In effect, the length and shape of the foot of the wearer shapes the fabric into a foot and heel configuration when the stocking is worn, resulting in a surprisingly good and comfortable fit even though the stocking has no permanently shaped heel.

The stocking of this invention is formed by knitting a seamless tube of an alternating pattern of yarns having opposite torque therein to provide stitch distortion and stretchability throughout the length of the tube, closing one end of the tube to form a toe end portion, and then boarding the tube on a novel hosiery form having a substantially straight heelless portion extending from the toe end portion and throughout at least that lower portion of the tube adapted to fit the foot and ankle of the wearer so that the stitch loops in this portion are heat-set in uniforrnly distorted condition to provide a substantial amount of uniform stretchability in this portion of the stocking.

The boarded stretch stocking of the present invention includes an open upper end having a welt formed thereon, a closed lower toe end, and a heelless tubular portion of uniformly stretchable fabric therebetween. At least that lower portion of the stretchable tubular portion which is adapted to fit the foot and ankle is substantially of the same width throughout and the stitch loops are heat-set in uniformly distorted condition so that the fabric has a high degree of uniform stretchability which permits the fabric to stretch to conform to the contour of the foot of the wearer with the result that a single size stocking can be made which will stretch to fit a full range of foot and leg sizes.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds when taken in connection with the accompanying drawings, in which- FIGURE 1 is a side elevation of a seamless tube in flattened condition and knit in accordance with the present invention and having the lower toe end portion closed with an arcuate seam;

FIGURE 2 is a side elevation of the boarded stretch stocking of the present invention in flattened condition; and

FIGURE 3 is a greatly enlarged fragmentary view of the fabric in the area enclosed by the dotted rectangle 3 in FIGURE 2 and illustrating the manner in which the stitch loops are distorted when the fabric is in partially stretched condition.

The stocking blank, shown in FIGURE 1, is knit on a circular knitting machine and a conventional turned welt 10 and shadow welt 11 are preferably knit of heavy denier multifilament non-stretchable nylon yarn, of about 45 denier. Then a substantially straight tubular portion T of stretch fabric is knit by forming an alternating pattern of courses of monofilament thermoplastic yarns having torque in opposite directions, such as 15 denier nylon. The torque in the yarns of the courses is in opposite directions to cause a distortion or inclination of the stitch loops in directions corresponding to the torque of the yarn. If

3 desired, the size of the stitch loops may be gradually reduced in the conventional manner as the tubular portion T is knit.

At the lower end of the stretchable tubular portion T, a toe end section 12 is preferably knit of a heavy denier non-stretchable yarn, such as 45 denier multifilament nylon, to provide reinforcement at the toe end of the stocking, in a manner to be presently described. The lower end of the stocking blank is then closed by an arcuate line of stitching or overedge seam extending across the toe end section 12, as indicated by the dotted line 13 in FIGURE 1. It is preferred that the stocking blank be turned wrong side out before the seaming operation. Then, as the overedge seam 13 is applied along the lower end of the stocking blank, the surplus fabric, indicated in dotted lines in FIGURE 1, is cut away in a conventional manner by the seaming machine. The stocking blank is then turned right side out so that the seam 13 is disposed on the inside of the stocking blank.

The stocking blank is then finished in the usual manner, including dyeing and boarding. The boarding may take place prior to or after dyeing or the stockings may be both preboarded and final boarded if desired. However, a novel boarding form without the usual heel projection is utilized to shape and form the stretch stocking of the present invention. The novel boarding form is formed of relatively thin sheet metal which is shaped to conform to the configuration of the boarded stocking shown in FIGURE 2. The stocking is drawn onto and uniformly stretched on the boarding form, and while in this condition the stocking is subjected to heat-setting treatment, usually in a steam pressure cabinet for a predetermined time interval. As the stocking blank (FIGURE 1) is drawn onto the novel boarding form, the stocking is stretched down on the board to a predetermined extent and thereby the stitch loops throughout the extent of the tubular stretchable portion T are in substantially uniformly distorted condition during the heat-setting process. Since the boarding form does not have a heel pocket forming bulge, there is no excessive stretching of the stocking on the boarding form while the boarding process is taking place with the result that the stretchability of the fabric is not reduced during the boarding operation, as would be the case when a tube stretch stocking is pulled onto and boarded on a conventional boarding form. When the stocking is removed from the boarding form, it has the unusual heelless configuration shown in FIGURE 2 heat-set therein.

For convenience of description, reference lines have been applied in FIGURE 2. The line A indicates the extent of the stretchable tubular portion of the stocking which extends from the lower edge of the shadow welt 11 to the upper edge of the closed toe end portion D. The stretchable tubular portion A is divided substantially equally into an upper half or calf, knee and thigh portion B and a lower half or foot portion C. The upper half B is adapted to fit the calf, knee and thigh area of the wearer while the lower half C is adapted to fit the foot, heel and ankle of the wearer.

The front edge of the boarded stocking (FIGURE 2) defines a substantially straight line from the open top edge of the welt to the lower end of the stretchable tubular portion A with a slight inward curve in the toe end portion D. The lower closed end, along the seam 13, curves upwardly along an arcuate path. The rear edge of the lower half C defines a substantially straight line parallel with the front edge so that the flattened tubular lower half C is substantially the same width throughout. This straight lower half C provides a heelless portion adapted to fit the foot, heel and ankle of the wearer. The rear edge of the upper half B gradually curves outwardly, in-

wardly and then outwardly to provide a suitable shape to aid in adapting this portion of the stocking to fit the calf, knee and thigh of the wearer. Thus, the upper half B progressively increases in width from the bottom to the tially a uniform Width.

Due to the flat nature of the boarding form, heat-set creases are formed along the front and rear edges of the stocking during the boarding operation. These front and rear creases are readily discernible in the finished stocking and may serve as an aid in properly positioning the stocking on the leg.

As shown in FIGURE 3, the courses 0-20, (1-21 and 0-22 have stitch loops which are distorted or inclined in alternating directions, corresponding to the direction of torque in the yarns. This distortion occurs because courses C-2!) and C-22 are knit of a yarn Y-l which has a torque in one direction and the course C-21 is knit of a yarn Y-2 which has a torque in the opposite direction. When the fabric is completely relaxed, the stitch loops distort to a much greater extent than that illustrated in FIGURE 3. The fabric has been illustrated in FIGURE 3 as being in a partially stretched condition to enable one to more easily follow the stitch construction. Generally, the use of monofilament torque yarn to form stretchable stockings is disclosed in US. Patent No. 2,771,759, issued Nov. 26, 1956.

It is preferred that the upper half B of the tubular portion of the stocking be shaped along its rear edge to generally conform to the configuration of the upper portion of the leg so that this upper rear portion generally conforms to the shape conventionally imparted to this portion of ladies stockings. This shaping of the rear upper edge of the stocking of the present invention aids in properly positioning the stocking on the leg, since there is no shaped foot and heel to aid the wearer. However, it is to be understood that the contour of the stocking can be varied as desired, e.g., it could be substantially the same width throughout, from the toe end D through the turned welt 10, or it could be slightly tapered from top to toe. It is important that the stocking maintain its generally tubular character and that the heel area be devoid of the usual excessively shrunken portion at the ankle and excessively stretched portion at the heel pocket.

The torque can be applied to the yarn in any well known and conventional manner, such as by heat-setting and twisting the yarn to impart substantial liveliness thereto. While the stocking is shown as being knit with plain stitches, it is to be understood that it could also be knit With other types of stitches. For example, it could contain tucks formed in a pattern with the plain stitches, in what is known as a micromesh pattern.

In the drawings and specification there have been set forth preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

-I claim:

1. A ladies boarded sheer seamless stretch tube stocking adapted to fit a wide range of foot and leg sizes, said stocking comprising an open upper end having a welt formed thereon, a closed lower toe end, and a heelless tubular portion therebetween, said tubular portion including an alternating pattern of courses of thermoplastic monofilament yarns having sutficient torque in opposite directions to cause the stitch loops to distort and incline in directions corresponding to the torque in the yarns and to impart substantial stretchability to the fabric of the tubular portion, at least that lower portion of said tubular portion adapted to fit the foot, heel and ankle being heelless and of substantially the same width throughout, and the stitch loops of said lower portion being heatset in uniformly distorted condition to provide a substantially high degree of uniform stretchability to the fabric throughout said lower portion.

2. A ladies stretch stocking according to claim 1 wherein the heelless lower portion is substantially onehalf the overall length of said tubular portion.

3. A ladies stretch stocking according to claim 2 wherein the front and rear creases define respective front and rear edges extending along opposite sides of said tubular portion, and including a seam extending across said closed lower toe end, said seam being arcuate and extending upwardly from said front edge to said rear edge.

4. A ladies stretch stocking according to claim 1 including front and rear creases extending along opposite sides of the stocking, the front crease being adapted to fit along the front of the leg and the top of the foot of the wearer, the front crease being substantially straight throughout the length of the stocking, and the rear crease being adapted to fit along the back of the leg and under the foot of the wearer.

5. A ladies stretch stocking according to claim 4 wherein the front and rear creases define respective front and rear edges extending along opposite sides of said tubular portion, said rear edge defines a straight line parallel to said front edge in the lower portion of the tubular portion, and the portion of said rear edge above the lower portion is curved to generally conform to the calf and thigh of the wearer.

6. A ladies stretch stocking according to claim 1 wherein the thermoplastic monofilament torque yarns of said tubular portion are 15 denier nylon.

6 References Cited by the Examiner UNITED STATES PATENTS 1,601,020 9/1926 Holden et al 66-178 1,715,657 6/1929 Holden et a1 66-178 2,699,056 1/ 1955 Margulies 66-178 X 2,736,945 3/1956 Burleson et a1 66-178 X 2,755,616 7/1956 Weller 66-178 X 2,825,215 3/1958 Backreus 66-178 2,841,971 7/1958 Bind et a1 66-178 2,960,751 11/1960 Reymes-Cole 66-185 X 2,968,937 1/1961 Margulies 66-1'85 X 3,077,757 2/1963 Bobo et al 66-178 3,089,323 5/1963 Jayorek 66-185 3,103,302 9/1963 Minton 223-75 X FOREIGN PATENTS 1,265,591 5/1961 France. 1,353,620 1/1964 France.

407,539 12/ 1924 Germany.

937,075 9/ 1963 Great Britain.

563,084 I 5/1957 Italy.

ROBERT R. MACKEY, Acting Primary Examiner. MERVIN STEIN, R. FELDBAUM, Assistant Examiners. 

1. A LADIES'' BOARDED SHEEER SEAMLESS STRETCH TUBE STOCKING ADAPTED TO FIT A WIDE RANGE OF FOOT AND LEG SIZES, SAID STOCKING COMPRISING AN OPEN UPPER END HAVING A WELT FORMED THEREON, A CLOSED LOWER TOE END, AND A HEELLESS TUBULAR PORTION THEREBETWEEN, SAID TUBULAR PORTION INCLUDING AN ALTERNATING PATTERN OF COURSES OF THERMOPLASTIC MONOFILAMENT YARNS HAVING SUFFICIENT TORQUE IN OPPOSITE DIRECTIONS TO CAUSE THE STITCH LOOPS TO DISTORT AND INCLINE IN DIRECTIONS CORRESPONDING TO THE TORQUE IN THE YARNS AND TO IMPART SUBSTANTIAL STRETCHABILITY TO THE FABRIC OF THE TUBULAR PORTION, AT LEAST THAT LOWER PORTION OF SAID TUBULAR PORTION ADAPTED TO FIT THE FOOT, HEEL AND ANKLE BEING HEELLESS AND OF SUBSTANTIALLY THE SAME WIDTH THROUGHOUT, AND THE STITCH LOOPS OF SAID LOWER PORTION BEING HEATSET IN UNIFORMLY DISTORTED CONDITION TO PROVIDE A SUBSTANTIALLY HIGH DEGREE OF UNIFORM STRETCHABILITY TO THE FABRIC THROUGHOUT SAID LOWER PORTION. 